Collapsible crate

ABSTRACT

A collapsible crate including a generally rectangular bottom panel having two pairs ed edges, a first side, and a second side; at least two side panels, one each hingedly along a first pair of the opposed bottom panel edges; and at least two end panels, one each hingedly attached along a second pair of opposed bottom edges. The at least two side re foldable between a collapsed position substantially parallel to the first side of the panel and a set up position extending upward from the bottom panel. The at least two panels are foldable between a position substantially parallel to the second side of the bottom panel and a set up position extending upward from the bottom panel. The side panels, end panels and bottom panel, can be connected together to define a generally box shaped the set up position.

BACKGROUND

1. Field of the Invention

The present disclosure is generally directed to storage devices, and more particularly to collapsible storage crates.

2. Description of Related Art

Storage and transportation devices have traditionally included crate type devices which may be used to store and/or transport a myriad of products. These crates may be constructed of wood, plastic, metal or any other suitable material. Mostly, these storage crates are small enough to be carried by a single person using one or both hands and may include handles or holes on the sides for grasping.

A significant drawback to these crates from a retail sales point of view occurs in bulk transportation of such crates and in display of such crates for sale. Because crates are typically made to hold a plurality of objects, they may consist mostly of empty space, surrounded by four or more walls and include a bottom. During bulk transportation from the manufacturer to the retailer, the volume of empty space within the crate may be lost to the shipper and may result in a higher per unit cost to the retailer.

In an attempt to solve the problems mentioned above, collapsible crates have been designed wherein the walls may collapse thereby reducing the potentially empty volume during shipping. These designs, while at least partially successful in reducing lost transportation volume, have generally been manufactured out of plastic and are not strong enough to support the transportation and/or storage of heavier objects including files for file storage.

Further, previous attempts to design collapsible storage crates have not been successful in optimizing transportation “cube,” or in other words, the volume that the crate's master carton occupies. Previous attempts have also failed to significantly reduce stocking time and/or to optimize retail shelf space.

BRIEF DESCRIPTION OF THE DRAWINGS

Objects, features, and advantages of the present invention will become apparent upon reading the following description in conjunction with the drawing figures, in which:

FIG. 1 illustrates a perspective view of one example of a collapsible crate in a set up condition and constructed in accordance with the teachings of the present invention.

FIG. 2 illustrates the collapsible crate of FIG. 1 in a folded condition.

FIG. 3 illustrates a perspective view of the collapsible crate of FIG. 1 in an unfolded condition and showing the interior surfaces of the collapsible crate.

FIG. 4 illustrates a perspective view of the unfolded crate of FIG. 3 and shows the exterior surfaces of the collapsible crate.

FIG. 5 illustrates a perspective view of a support rod used in the collapsible crate of FIG. 1.

FIG. 6 illustrates a perspective view of a side panel of the collapsible crate of FIG. 1.

FIG. 7 illustrates a fragmentary view of an interior top corner of a side panel and an end panel of the storage crate of FIG. 1.

FIG. 8 illustrates an end view of the storage crate of FIG. 1 in a folded condition.

FIG. 9 illustrates two storage crates, similar to the storage crate of FIG. 1, and stacked one on top of the other.

DETAILED DESCRIPTION OF THE DISCLOSURE

A collapsible crate is disclosed herein which includes a bottom panel having two pairs of opposing edges and a first side and a second side. The crate also has two side panels spaced apart and opposing one another. The side panels are disposed adjacent a first pair of the opposing bottom edges. The crate also has two end panels spaced apart and opposing one another. The end panels are disposed adjacent a second pair of opposing bottom edges. The two side panels are hingedly attached to the first side of the bottom panel at an edge adjacent to the bottom panel and the two end panels are hingedly attached to the second side of the bottom panel at an edge adjacent to the bottom panel. The two side panels are foldable to a position substantially parallel and adjacent to the first bottom panel side. The two end panels are foldable to a position substantially parallel and adjacent to the second bottom panel side.

Referring now to the drawings, FIG. 1 shows one embodiment of a collapsible crate 10 constructed in accordance with the teachings of the present invention and in an assembled or set up condition. When in the set up condition, the collapsible crate 10 generally includes two side panels 12, and two end panels 14. The side panels 12 lie in planes substantially perpendicular to the planes of the end panels 14 to generally form a rectangular cylinder or box shape in this example. The collapsible crate 10 also includes a bottom panel 22 which lays in a plane substantially perpendicular to both the side panels 12 and the end panels 14 in the assembled or set up condition. In this example, a support rod 40 is configured and positioned to both secure the side panels 12 and the end panels 14 in the set up condition and also to provide a support for hanging file folders if required. Openings 20 are formed in each end panel 14 in the disclosed example and serve as hand holds for a user to grasp during movement of the collapsible crate 10.

FIG. 2 is an illustration of the collapsible crate 10 of FIG. 1 in a folded or broken down condition. In this view, the end panels 14 are folded to a position generally parallel to and above the bottom panel 22 and the side panels 12 are folded to a position generally parallel to and below to the bottom panel 22. Top and bottom are relative terms for description in this figure and if the storage crate were reversed, the end panels 14 and the side panels 12 would be reversed accordingly. Regardless, in the folded condition, the end panels 14 are disposed substantially parallel and adjacent to each other and substantially parallel to the bottom panel 22. Further, in the folded condition, the pair of end panels 14 is adjacent a first side of the bottom panel 22. Likewise, in the folded condition of FIG. 2, the side panels 12 are substantially parallel and adjacent one another and the pair of side panels 12 is adjacent a second side of the bottom panel 22.

FIG. 3 illustrates the interior surfaces of the collapsible crate 10 of FIG. 1 in a laid out, flat or unfolded condition. The flat or unfolded condition of FIG. 3 is a transition or intermediate configuration between the folded condition of FIG. 2 and the set up condition of FIG. 1. As is seen in FIG. 3, the side panels 12 are substantially rectangular in shape and have four edges 13, one of which 13 a is adjacent a first bottom panel edge 21 a. Each side panel 12 in this example is attached to the bottom panel 22 with a pair of hinges 24. Specifically, each hinge 24 is attached to an inner side panel surface 23 and an inner bottom panel surface 32. The hinges 24 may be any type of hinge which allows the side panels 12 and end panels 14 to be positioned as described above. The hinges 24 may include, but are not limited to butt hinges, loose joint hinges, utility hinges, final tipped hinges, strap hinges, no mortise hinges, tee hinges, etc.

FIG. 4 illustrates the exterior surfaces of the collapsible crate 10 of FIG. 1 in the laid out, flat or unfolded condition. In a manner similar to the side panels 12 discussed in FIG. 3, the end panels 14 are substantially rectangular in shape, and have four edges 15, one of which 15 a is adjacent a second bottom panel edge 21 b. Each end panel 14 in this example is attached to the bottom panel with a pair of hinges 34. Specifically, each hinge 34 is attached to an outer end panel surface 36 and an outer bottom surface 38. The hinges 34 are substantially identical to the hinges 24 in this example.

The size and shape of the panels can vary. Additionally, hinge construction can also vary without departing from the spirit and scope of the invention. For example, the hinges may be sized to allow the side panels to lie substantially parallel to one another in the folded condition. Further, the bottom panel 22 as described above is substantially rectangular in shape, but the size and shape of the bottom panel 22 may also vary.

FIG. 5 illustrates a support rod 40 used in this example to secure the side panels 12 to the end panels 14 as will be further discussed with respect to FIG. 7. The support rod 40 in the embodiment of FIG. 5 is essentially a cylindrical tube including an elongate support section 42 and two connection sections 44, one connection section 44 from each end of the elongate support section 42. The connection sections 44 are essentially perpendicular to the elongate support section 42 in this example. The connection sections 44 are connected to the elongate support section 42 with a convoluted turn and step portion 46 offsetting an axis of the connection sections 44 from the axis of the elongate support section 42. The offset provides separation or offset of the elongate support section 42 from the side panels 12.

FIG. 6 illustrates a side panel 12 of the collapsible crate 10 of FIG. 1. The side panel 12 includes two or more connectors 54 disposed on the inner surface 23 of the side panel. Similarly, the end panels 14 may also include connectors 56 disposed on the inner surface 25 of the end panels 14 (see FIG. 3 for reference to the inner surface of the end panels). The connectors 54 of the side panels 12 and the connectors 56 of the end panels (best seen in FIG. 7) receive the support rod connection sections 44 therein to secure the side panels 12 and the end panels 14 in the set up condition as will be further discussed with respect to FIG. 7. The connectors 54 and 56 are generally disposed on the side panels 12 and the end panels 14 near a side edge 13 b (with respect to the side panels 12) or 15 b (with respect to the end panels 14 in FIG. 4). Additionally, the connectors 54 and 56 in this example are disposed generally near a top edge 13 c (with respect to the side panels 12) or 15 c (with respect to the end panels 14 in FIG. 4). The connectors 54 and 56 are generally tubular in shape and include a hollow interior sized to receive the outer diameter of the connection sections 44 of the support rod 40. Further, the axis of opening of the connectors 54 and 56 is generally aligned with the side edges 13 b or 15 b of the respective side panels 12 and end panels 14. The connectors 54 and 56 may be rigidly attached to the side panels 12 or end panels 14 by any means necessary, for example, glue, welding, etc.

FIG. 7 illustrates a corner section of the collapsible crate 10 of FIG. 1. In the assembled condition, the side panel 12 and the end panel 14 are arranged substantially perpendicular to each other and both the side panel 12 and the end panel 14 are also arranged substantially perpendicular to the bottom panel 22. The connectors 54 of the side panel 12 are positioned adjacent to and aligned with the connectors 56 of the end panel 14. In this example, the connectors 54 are above the connectors 56. The longitudinal axes of the connectors 54 and 56 are generally aligned to allow the support rod connection sections 44 to be received substantially through each of the aligned connectors 54 and 56. The user essentially inserts the support rod connection sections 44 into the connectors 54 and 56 in the direction of arrow A to secure the side panel 12 and the end panel 14 in position relative to one another in the set up condition. A similar operation is performed at each of the other three corners of the collapsible crate 10 such that the side panels 12, end panels 14 and the bottom panel 22 substantially form a box which includes an opening and a storage space disposed within the box (best seen in FIG. 1). One support rod 40 will secure one side panel 12 to two end panels 14.

FIG. 8 is a further illustration of the collapsible crate 10 in the folded condition. The view of FIG. 8 is a side view showing the panels in the folded condition. FIG. 8 further illustrates the compactness of the collapsible crate 10 in the folded condition. The bottom panel 22 is essentially “sandwiched” between the two side panels 12 on one side and the two end panels 14 on the other side.

FIG. 9 illustrates two collapsible crates 10 and 10′ stacked one upon the other as may be used to conserve and optimize use of storage space when the collapsible crates 10 contain storage materials. The collapsible storage crate 10 in this example has a tab 62 disposed near a bottom edge 15 of each end panel 14 and a foot 64 disposed near a bottom edge 13 of each side. The tabs 62 and feet 64 generally extend below the bottom edge 13 a or 15 a (as seen in FIGS. 3 and 4) of the side panel 12 or end panel 14 to overlap a top edge of a side panel 12 or an end panel 14 of the bottom collapsible crate 10′ and serve to stabilize the top collapsible crate 10 on the bottom collapsible crate 10′ by preventing relative movement in a horizontal plane between the two collapsible crates 10 and 10′. Essentially, the upper collapsible crate 10 registers with the lower collapsible crate 10′.

Referring once again to FIG. 1, collapsible crates 10 and 10′ may be dimensioned to allow both letter sized hanging file folders 72 and legal sized hanging file folders 74 to be disposed therein. In the embodiment of FIG. 1, a letter sized hanging file folder 72 may be disposed within the collapsible crate 10′ such that the ears of a standard suspension file folder are supported by and between the support rods 40. A legal sized file folder 74 can be disposed within the collapsible crate 10′ such that the ears of the folder are supported on the top edges of the end panels 14. Additionally, the collapsible crate 10 may include one or more wheels 70 disposed thereon.

The collapsible crate 10 disclosed herein may be constructed out of any suitable material, such as, for example, metal mesh, plastic, wood, corrugated paper, etc. The side panels may be made in similar or different colors according to user preferences. Further, the hinges 24 and 34 may be any known or unknown type of hinge and may be formed from virtually any type of material, such as metal or plastic. Additionally, the hinges may be non-traditional type hinges, such as, for example Velcro strips with plastic loops, or quick release type nylon straps and buckles. The connectors 54 and 56 may also be constructed from virtually any type material, such as metal, plastic or ceramic and may be attached to the side panels 12 and the end panels 14 by any suitable means, such as glue, welding or sewing.

A further advantage of the present invention is that the collapsible crate 10 may be stored with a plurality of other collapsible crates in a master container for shipping. In one embodiment, the master container may include five collapsible crates 10 in the folded condition. The master carton may be sized to optimize pallet cube during transportation and retail shelf space during display for sale. Additionally, the collapsible crates 10 need not be removed from the master carton when displayed for sale, thereby reducing restocking time for the retailer.

Although certain embodiments of a mesh crate have been described herein in accordance with the teachings of the present disclosure, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all embodiments of the teachings of the disclosure that fairly fall within the scope of permissible equivalents. 

1. A collapsible crate comprising: a generally rectangular bottom panel having two pairs of opposed edges, a first side, and a second side; at least two side panels, one each hingedly attached along a first pair of the opposed bottom panel edges; at least two end panels, one each hingedly attached along a second pair of opposed bottom edges; wherein the at least two side panels are foldable between a collapsed position substantially parallel to the first side of the bottom panel and a set up position extending upward from the bottom panel; wherein the at least two end panels are foldable between a position substantially parallel to the second side of the bottom panel and a set up position extending upward from the bottom panel, and wherein the side panels, end panels and bottom panel, can be connected together to define a generally box shaped crate in the set up position.
 2. The collapsible crate as in claim 1, wherein the side panels and the end panels include connectors generally hollow and disposed at an upper portion of a side edge of the side panel and a side edge of the end panel, and oriented with a longitudinal axis generally parallel to the side edge of the side panel and the side edge of the end panel.
 3. The collapsible crate as in claim 2, further including a pair of support rods, each having a support section, a connection section and a convoluted turn section, wherein the connection section of the support rod is at least partially inserted into each pair of adjacent connectors to secure the side panels and end panels in position relative one another.
 4. A collapsible crate as in claim 3, wherein the end panels are dimensioned such that when the collapsible crate is in the set up condition, a letter-sized hanging file folder can be suspended between the at least two side panels and between and from the support rods.
 5. A collapsible crate as in claim 3, wherein the side panels are dimensioned such that when the collapsible crate is in the set up condition, a legal-sized hanging file folder can be suspended between and from the at least two end panels.
 6. A collapsible crate as in claim 1, wherein the at least two side panels, the at least two end panels, and the bottom panel are made from a metal mesh material.
 7. A collapsible crate as in claim 1, wherein the at least two side panels, the at least two end panels, and the bottom panel are made from a plastic material.
 8. A collapsible crate as in claim 1, wherein a plurality of tabs is attached to each of the least one end panels along a bottom edge and generally near a side edge of the end panels.
 9. A collapsible crate as in claim 8, wherein the tabs stabilize and substantially prevent relative movement of the collapsible crate when the collapsible crate is stacked on top of a second collapsible crate of similar construction, both in the set up condition.
 10. A collapsible crate as in claim 1, wherein a plurality of feet is attached to each of the least one side panels along a bottom edge and generally near a side edge of the side panels.
 11. A collapsible crate as in claim 10, wherein the tabs stabilize and substantially prevent relative movement of the collapsible crate when the collapsible crate is stacked on top of a second collapsible crate of similar construction, both in the set up condition.
 12. A collapsible crate as in claim 1, including a plurality of wheels.
 13. A collapsible crate as in claim 1, wherein the at least two side panels are attached to the first pair of opposed bottom edges with a hinge.
 14. A collapsible crate as in claim 13, wherein the hinge is sized to allow the two side panels to lie substantially parallel to one another when the two side panels are in the folded condition.
 15. A collapsible crate as in claim 1, wherein the at least two end panels are attached to the second pair of opposed bottom edges with a hinge.
 16. A collapsible crate as in claim 15, wherein the hinge is sized to allow the two end panels to lie substantially parallel to one another when the two end panels are in the folded condition.
 17. A collapsible crate comprising: a generally rectangular bottom panel having two pairs of opposed edges, a first side, and a second side; at least two side panels, one each hingedly attached along a first pair of the opposed bottom panel edges; at least two end panels, one each hingedly attached along a second pair of opposed bottom edges; wherein the at least two side panels are foldable between a collapsed position substantially parallel to the first side of the bottom panel and a set up position extending upward from the bottom panel; wherein the at least two end panels are foldable between a position substantially parallel to the second side of the bottom panel and a set up position extending upward from the bottom panel, wherein the side panels, end panels and bottom panel, can be connected together to define a generally box shaped crate in the set up position; wherein the side panels and the end panels include connectors that are generally hollow and disposed at an upper portion of a side edge of the side panel and an upper portion of a side edge of the end panel, and oriented with a longitudinal axis generally parallel to the side edge of the side panel and the side edge of the end panel; and a pair of support rods, each having a support section, a connection section and a convoluted turn section, wherein the connection section of the support rod is at least partially inserted into a pair of adjacent connectors to secure the side panels and end panels in position relative one another 